Mitigating lost circulation
A eutectic metal alloy is placed through a coiled tubing into a wellbore formed in a subterranean formation. The eutectic metal alloy includes a mixture of multiple metals. The eutectic metal alloy has a melting temperature that is less than a melting temperature of each individual metal of the multiple metals making up the eutectic metal alloy. The eutectic metal alloy is heated to a temperature equal to or greater than the melting temperature of the eutectic metal alloy to liquefy the eutectic metal alloy. The liquefied eutectic metal alloy is flowed from the wellbore and into the subterranean formation, thereby exposing the liquefied eutectic metal alloy to a specified downhole temperature within the subterranean formation and causing the liquefied eutectic metal alloy to solidify to form a seal. The seal prevents fluid from flowing from the wellbore and into the subterranean formation.
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This disclosure relates to mitigation of lost circulation in subterranean formations.
BACKGROUNDIn oil or gas well drilling, cementing, completions, and workovers, lost circulation is an undesirable situation in which drilling fluid, also known as mud, flows into a subterranean formation instead of returning up to the surface. In partial lost circulation, mud continues to flow to the surface with some loss of mud to the formation. In total lost circulation, all the mud flows into the formation with no return to the surface. The consequences of lost circulation can range from a loss of drilling fluid to blowout or even loss of life. Prevention of lost circulation is desirable, but because lost circulation is such a common occurrence, remediation methods can help mitigate lost circulation when it has occurred.
SUMMARYThis disclosure describes technologies relating to mitigating lost circulation in wells. Certain aspects of the subject matter described can be implemented as a method. A eutectic metal alloy is placed, for example, via pipe, wireline, or coiled tubing into a wellbore formed in a subterranean formation. The eutectic metal alloy includes a mixture of metals. The eutectic metal alloy has a melting temperature that is less than a melting temperature of each individual metal of the multiple metals making up the eutectic metal alloy. The eutectic metal alloy is heated to a temperature equal to or greater than the melting temperature of the eutectic metal alloy to liquefy the eutectic metal alloy. The liquefied eutectic metal alloy is flowed from the wellbore and into the subterranean formation, thereby exposing the liquefied eutectic metal alloy to a specified downhole temperature within the subterranean formation and causing the liquefied eutectic metal alloy to solidify to form a seal, for example, in the fracture-formation matrix. The seal prevents fluid from flowing from the wellbore and into the subterranean formation.
This, and other aspects, can include one or more of the following features. Heating the eutectic metal alloy can include placing a cable heater coupled to the coiled tubing at a downhole location within the wellbore and providing power to the cable heater. The cable heater can include a heating element, an insulation layer, and a sheath. The heating element can be configured to generate heat in response to receiving power. The insulation layer can surround the heating element. The insulation layer can include magnesium oxide. The sheath can surround the insulation layer. The sheath can include steel. Prior the placing the eutectic metal alloy with the coiled tubing into the wellbore, a packer or a bridge plug can be positioned downhole of the downhole location within the wellbore. After positioning the packer or bridge plug and prior to placing the eutectic metal alloy with the coiled tubing into the wellbore, the bridge plug or packer can seal against an inner wall of the wellbore, thereby preventing fluid from flowing further downhole past the bridge plug or packer. The eutectic metal alloy can have a density of at least about 8.0 grams per cubic centimeter (g/cm3). The eutectic metal alloy can have a density in a range of from about 8.0 g/cm3 to about 11.0 g/cm3. The eutectic metal alloy can include particles having an average particle size in a range of from about 1 micrometer to about 0.25 centimeters. The liquefied eutectic metal alloy can have a viscosity of less than 10 centipoise (cP) or less than 5 cP. The liquefied eutectic metal alloy can have a viscosity in a range of from about 1 cP to about 10 cP or from about 1 cP to about 5 cP. The eutectic metal alloy can be suspended in a carrier fluid. The carrier fluid can include bentonite clay. The carrier fluid can include a polymer and a crosslinking agent. The crosslinking agent can be configured to crosslink the polymer in response to exposure to the specified downhole temperature to slow down loss of fluid. The seal can include the solidified eutectic metal alloy distributed across a crosslinked polymer matrix. Bentonite clay or polymer can include the solidified eutectic metal alloy distributed throughout the carrier fluid. The polymer can include hydroxyethyl cellulose.
Certain aspects of the subject matter described can be implemented as a system. The system includes a coiled tubing (or drill pipe), a lost circulation fluid, and a cable heater. The coiled tubing is disposed in a wellbore formed in a subterranean formation. The coiled tubing is configured to enable flow of the lost circulation fluid. The lost circulation fluid is configured to seal a lost circulation zone at a downhole location in the subterranean formation. The lost circulation fluid includes a eutectic metal alloy. The eutectic metal alloy includes multiple metals. The eutectic metal alloy has a melting temperature that is less than a melting temperature of each metal of the multiple metals that make up the eutectic metal alloy. The eutectic metal alloy is configured to liquefy in response to being heated to a temperature equal to or greater than the melting temperature of the eutectic metal alloy. In some implementations, the lost circulation fluid includes a carrier fluid. In such implementations, the eutectic metal alloy is suspended in the carrier fluid. The eutectic metal alloy, in a liquefied state in response to being heated to the temperature equal to or greater than the melting temperature of the eutectic metal alloy, is configured to flow from the wellbore and into the subterranean formation. In implementations where the eutectic metal alloy is carried by the carrier fluid, the carrier fluid is configured to gel in response to exposure to a specified downhole temperature to form a seal with the eutectic metal alloy distributed across the seal. The seal is configured to prevent fluid from flowing from the wellbore and into the subterranean formation. The cable heater is coupled to the coiled tubing flowing the lost circulation fluid. The cable heater is located at the downhole location. The cable heater is configured to, in response to receiving power at the downhole location, heat the eutectic metal alloy to the temperature equal to or greater than the melting temperature of the eutectic metal alloy to liquefy the eutectic metal alloy.
This, and other aspects, can include one or more of the following features. The cable heater can include a heating element, an insulation layer, and a sheath. The heating element can be configured to generate heat in response to receiving power. The insulation layer can surround the heating element. The insulation layer can include magnesium oxide. The sheath can surround the insulation layer. The sheath can include steel. The system can include a bridge plug or packer positioned downhole of the downhole location within the wellbore. The bridge plug or packer can be sealed against an inner wall of the wellbore to prevent fluid from flowing further downhole past the bridge plug or packer. The eutectic metal alloy can have a density of at least 8.0 g/cm3. The eutectic metal alloy can have a density in a range of from about 8.0 g/cm3 to about 11.0 g/cm3. The eutectic metal alloy can include particles having an average particle size in a range of from about 1 micrometer to about 0.25 centimeters. The liquefied eutectic metal alloy can have a viscosity of less than 5 cP. The liquefied eutectic metal alloy can have a viscosity in a range of from about 1 cP to about 5 cP. The carrier fluid can include bentonite clay. The carrier fluid can include a polymer and a crosslinking agent. The crosslinking agent can be configured to crosslink the polymer in response to exposure to the specified downhole temperature to form the seal. The seal can include the solidified eutectic metal alloy distributed across a crosslinked polymer matrix. The polymer can include hydroxyethyl cellulose.
Certain aspects of the subject matter described can be implemented as a method. A packer is positioned within a wellbore formed in a subterranean formation. The packer is expanded to seal against an inner wall of the wellbore, thereby preventing fluid from flowing past the packer. A lost circulation fluid is flowed through a coiled tubing into the wellbore. The lost circulation fluid includes a eutectic metal alloy and a carrier fluid. The eutectic metal alloy includes a mixture of multiple metals. The eutectic metal alloy has a melting temperature that is less than a melting temperature of each individual metal of the multiple metals making up the eutectic metal alloy. The carrier fluid includes hydroxyethyl cellulose and a crosslinking agent. The eutectic metal alloy is suspended in the carrier fluid. A cable heater coupled to the coiled tubing is placed at a downhole location within the wellbore, up hole of the expanded packer. After placing the cable heater at the downhole location, power is provided to the cable heater, thereby heating the eutectic metal alloy to a temperature greater than the melting temperature of the eutectic metal alloy to liquefy the eutectic metal alloy. The liquefied eutectic metal is flowed with the carrier fluid from the wellbore and into the subterranean formation, thereby exposing the carrier fluid and the eutectic metal alloy to a specified downhole temperature within the subterranean formation and causing the crosslinking agent to crosslink the hydroxyethyl cellulose and the eutectic metal alloy to solidify to form a seal. The seal includes the eutectic metal alloy (solidified) distributed across a crosslinked polymer matrix. The seal prevents fluid from flowing from the wellbore and into the subterranean formation. The packer is drilled through to remove the packer from the wellbore.
This, and other aspects can include one or more of the following features. The eutectic metal alloy can have a density of at least about 8.0 g/cm3. The eutectic metal alloy can have a density in a range of from about 8.0 g/cm3 to about 11.0 g/cm3. The eutectic metal alloy can include particles having an average particle size in a range of from about 1 micrometer to about 0.25 centimeters. The liquefied eutectic metal alloy can have a viscosity of less than 5 centipoise (cP). The liquefied eutectic metal alloy can have a viscosity in a range of from about 1 cP to about 5 cP. The eutectic metal alloy can be suspended in a carrier fluid. The carrier fluid can include bentonite clay. The process can be repeated at a different downhole location where the subterranean formation is depleted/weakened to mitigate lost circulation.
The details of one or more implementations of the subject matter of this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
This disclosure describes mitigating lost circulation in wells. The process includes flowing a eutectic metal alloy (in various forms, including solid particles or liquid suspensions) to a desired location in the well and using mineral insulated (MI) heating to melt the eutectic metal alloy. The liquefied alloy then flows into a desired zone in the subterranean formation and solidifies to form a seal. The process can be carried out by the use of coiled tubing and is repeatable, unlike conventional methods, for example, that use thermite. Conventional methods that use thermite heating can also be used to melt the eutectic metal alloy and seal a zone, but MI heating allows for more precise control of temperature and allows for continuous heating in downhole heating applications. Thus, multiple treatments with the eutectic metal alloy (or a different eutectic metal alloy) can be performed. The eutectic metal alloy can be, for example, in the form of beads or a powder suspended in a carrier fluid. In some implementations, the eutectic metal alloy is flowed to the desired location with a carrier fluid including a mixed metal oxide compound and bentonite clay. In some implementations, the eutectic metal alloy is flowed to the desired location with a carrier fluid including a cross-linked hydroxyethyl cellulose or a fiber-laden fluid in which the fibers provide a mechanical force for suspending the dense eutectic metal alloy particles.
The subject matter described in this disclosure can be implemented, to realize one or more of the following advantages. In contrast to conventional lost circulation mitigation processes that utilize thermite, MI heating can be deployed using coiled tubing. The processes and systems described can be used to control the location of the zone for heating within the subterranean formation. In contrast to conventional lost circulation mitigation processes that utilize thermite, MI heating can repeatedly treat a desired zone within the subterranean formation without requiring a pulling out of the hole (POOH) operation. The processes and systems described can be used to provide precise temperature control for heating the desired zone within the subterranean formation. In contrast to conventional lost circulation mitigation processes that utilize thermite, MI heating can provide continuous heat to the desired zone within the subterranean formation. The processes and systems described can be used to treat multiple zones within the subterranean formation without requiring a POOH operation. The processes and systems described can be implemented by deployment of MI heater(s) separate from a bottomhole assembly (BHA) or drill pipe, which can be less labor-intensive in comparison to conventional processes which use thermite heaters, which can require attachment to a drill pipe. In some implementations, the core of the MI heater can include an alloy that allows the MI heater to function as a Curie heater. For example, the alloy (making up the core of the MI heater) can be selected such that once its Curie temperature is reached, the temperature output of the MI heater remains the same regardless of power input to the MI heater. The Curie temperature of a material is the temperature above which the material loses its permanent magnetic properties.
In some implementations, the well 100 is a gas well that is used in producing hydrocarbon gas (such as natural gas) from the subterranean zones of interest 110 to the surface 106. While termed a “gas well,” the well need not produce only dry gas, and may incidentally or in much smaller quantities, produce liquid including oil, water, or both. In some implementations, the well 100 is an oil well that is used in producing hydrocarbon liquid (such as crude oil) from the subterranean zones of interest 110 to the surface 106. While termed an “oil well,” the well not need produce only hydrocarbon liquid, and may incidentally or in much smaller quantities, produce gas, water, or both. In some implementations, the production from the well 100 can be multiphase in any ratio. In some implementations, the production from the well 100 can produce mostly or entirely liquid at certain times and mostly or entirely gas at other times. For example, in certain types of wells it is common to produce water for a period of time to gain access to the gas in the subterranean zone. The concepts herein, though, are not limited in applicability to gas wells, oil wells, or even production wells, and could be used in wells for producing other gas or liquid resources or could be used in injection wells, disposal wells, or other types of wells used in placing fluids into the Earth.
During drilling of the well 100, operators may encounter a lost circulation scenario. In such cases, it may be necessary to halt drilling and mitigate the lost circulation. Mitigating and/or remedying the lost circulation in the well 100 can include flowing a lost circulation fluid 150 into the well 100. The lost circulation fluid 150 can be placed in a desired location within the well 100 (for example, the location of lost circulation) and form a seal to prevent fluid from flowing from the wellbore 102 and into the subterranean formation, thereby mitigating and/or remedying the lost circulation. Thermal modeling can be implemented to determine the optimal location for delivering the lost circulation fluid 150. For example, the desired location within the well 100 can be at the location of lost circulation (sometimes referred to as loss zone) or directly up hole of that location. Once the lost circulation fluid 150 is placed in the desired location within the well 100, the lost circulation fluid 150 can be heated to a temperature at which a component of the lost circulation fluid 150 melts/liquefies (for example, a melting point of a eutectic metal alloy 150a). Once liquefied, the alloy penetrates into the subterranean formation and flows into the pore(s)/fracture(s) of the subterranean formation. The formation temperature is cooler than the melting point of the eutectic metal alloy 150a and therefore causes the eutectic metal alloy 150a to cool rapidly, which in turn solidifies the eutectic metal alloy 150a. In some implementations, solidification of the eutectic metal alloy 150a in response to cooling upon exposure to the cooler formation temperature of the subterranean formation causes the eutectic metal alloy 150a to expand in volume, which further facilitates the sealing function of the seal that is formed. For example, solidification of the eutectic metal alloy 150a (from a liquid state to a solid state) can cause the eutectic metal alloy 150a to expand in volume in a range of from about 1% to about 3% or from about 1% to about 2%.
The lost circulation fluid 150 includes the eutectic metal alloy 150a. In some implementations, the lost circulation fluid 150 includes a carrier fluid 150b. The eutectic metal alloy 150a can be suspended in the carrier fluid 150b. In some implementations, the carrier fluid 150b can be omitted, and the eutectic metal alloy 150a can be delivered to a desired location in the well 100 independent of the carrier fluid 150b. The eutectic metal alloy 150a includes a mixture of metals. The eutectic metal alloy 150a has a melting temperature that is less than the melting temperature of each individual metal making up the eutectic metal alloy 150a. In some implementations, the eutectic metal alloy 150a has a density of at least about 8.0 grams per cubic centimeter (g/cm3). For example, the eutectic metal alloy 150a has a density in a range of from about 8.0 g/cm3 to about 15.0 g/cm3, from about 8.0 g/cm3 to about 14.0 g/cm3, from about 8.0 g/cm3 to about 13.0 g/cm3, from about 8.0 g/cm3 to about 12.0 g/cm3, from about 8.0 g/cm3 to about 11.0 g/cm3, or from about 8.0 g/cm3 to about 10.0 g/cm3. In some implementations, the eutectic metal alloy 150a is in bead or powder form. In some implementations, the eutectic metal alloy 150a includes particles that have an average particle size (for example, average diameter) in a range of from about 1 micrometer to about 0.25 centimeters. In some implementations, the eutectic metal alloy 150a (in a liquefied state) has a viscosity in a range of from about 1 centipoise (cP) to about 10 cP. For example, the liquefied eutectic metal alloy 150a has a viscosity that is less than 5 cP. For example, the liquefied eutectic metal alloy 150a has a viscosity that is similar to the viscosity of water.
In some implementations, the carrier fluid 150b includes metal oxides, such as silicon oxide, aluminum oxide, and iron oxide. For example, the carrier fluid 150b can include bentonite clay, sepiolite clay, attapulgite clay, or hectorite clay. In some implementations, the carrier fluid 150b includes a polymer and a crosslinking agent. In such implementations, the crosslinking agent is configured to crosslink the polymer to form a crosslinked polymer matrix. Examples of polymers that can be included in the carrier fluid 150b include hydroxyethyl cellulose, guar gum, polysaccharides (such as alginate), or polyacrylates. Examples of a crosslinking agent that can be included in the carrier fluid 150b are metal ions, such as chromium ions, titanium ions, zirconium ions, or aluminum ions.
At stage (ii), the carrier fluid 150b has gelled to form a seal 209. Ceasing power delivery to the cable heater 207 allows for the eutectic metal alloy 150a to cool and re-solidify. The seal 209 that has formed includes the eutectic metal alloy 150a (re-solidified) distributed across the seal 209. The re-solidified eutectic metal alloy 150a provides structural stability and reduced permeability to the seal 209. The seal 209 is configured to prevent fluid from flowing from the subterranean formation and into the wellbore 102. Thus, the seal 209 has mitigated and/or eliminated the lost circulation in the well 100. The cable heater 207 can be POOH.
At stage (iii), drilling can be re-started. The drill bit 211 can be rotated to mill a portion of the seal 209 that is positioned within the wellbore 102. The drill bit 211 can be rotated to mill the packer 201 that was placed in stage (i). Thus, the drill bit 211 can be rotated and mill through the seal 209 and the packer 201 and drill further downhole to continue drilling the wellbore 102 (for example, to increase the length of the wellbore 102 to penetrate deeper into the subterranean formation).
At stage (iv), the drill bit 211 has drilled through the seal 209 and the packer 201 and has drilled deeper into the subterranean formation. The lost circulation zone 203 has been mitigated and is no longer a lost circulation zone. The zone is labeled as a remedied zone 203a in stage (iv). If another lost circulation situation arises, the process can be repeated for the new lost circulation zone.
The system 400A can include various sensors for monitoring activity during experimentation. For example, the system 400A includes temperature sensor(s), pressure sensor(s), and/or resistance meter(s). In the implementation shown in
For a specific experiment, the eutectic metal alloy 150a tested was a bismuth-based metal alloy. The bismuth-based metal alloy had a density of 8.546 g/cm3. The system 400A allowed for injection of molten bismuth (150a) into a core sample held by the core sample holder 401 under isostatic stress at a temperature of 155° C. The core sample was saturated with brine before injection of the molten eutectic metal alloy 150a. The molten eutectic metal alloy 150a (bismuth) was injected at a constant rate of 0.02 cubic centimeters per minute (cc/min) with pressures monitored within 0.02% accuracy. The electrical resistance of the core sample was monitored by the resistance meter 421 at a 1 kilohertz (kHz) frequency to monitor bismuth entry and breakthrough. A control sample was tested with only brine, free of the bismuth-based metal alloy. Properties of the test sample (including the bismuth-based metal alloy) were measured prior to testing, after testing, after a tri-axial compression test, and after a tensile strength test (also referred to as a Brazilian test). The properties of the control sample and the test sample that were measured are provided in Tables 1 and 2.
-
- L is length.
- D is diameter.
- V is bulk volume.
- Vg is grain volume.
- Vp is pore volume.
- ρg is grain density.
- ρ is bulk density.
- ϕ is porosity.
- kb is brine permeability.
- kK is Klinkenberg permeability.
- md is dry weight.
- ms is saturated weight.
- Sb is bismuth saturation.
- Pc is capillary entry pressure.
- MCS is maximum compressive strength.
- BTS is Brazilian tensile strength.
- Es is Young's modulus (static).
- vs is Poisson's ratio (static).
- Ed is Young's modulus (dynamic).
- vd is Poisson's ratio (dynamic).
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
As used in this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.
As used in this disclosure, the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.
As used in this disclosure, the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.
Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “0.1% to about 5%” or “0.1% to 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.
Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in an order, this should not be understood as requiring that such operations be performed in the order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. In certain circumstances, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and performed as deemed appropriate.
Moreover, the separation or integration of various system modules and components in the previously described implementations should not be understood as requiring such separation or integration in all implementations, and it should be understood that the described components and systems can generally be integrated together or packaged into multiple products.
Accordingly, the previously described example implementations do not define or constrain the present disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of the present disclosure.
Claims
1. A method comprising:
- placing a eutectic metal alloy with a coiled tubing into a wellbore formed in a subterranean formation, the eutectic metal alloy comprising a plurality of metals, the eutectic metal alloy having a melting temperature that is less than a melting temperature of each individual metal of the plurality of metals, the eutectic metal alloy comprising particles and suspended in a carrier fluid comprising a polymer and a crosslinking agent, the crosslinking agent configured to crosslink the polymer in response to exposure to a specified downhole temperature;
- heating the eutectic metal alloy to a temperature equal to or greater than the melting temperature of the eutectic metal alloy to liquefy the eutectic metal alloy;
- flowing the liquefied eutectic metal alloy from the wellbore and into the subterranean formation, thereby exposing the liquefied eutectic metal alloy to the specified downhole temperature within the subterranean formation and causing the liquefied eutectic metal alloy to solidify to form a seal comprising the solidified eutectic metal alloy distributed across a crosslinked polymer matrix; and
- preventing, by the seal, fluid from flowing from the wellbore and into the subterranean formation.
2. The method of claim 1, wherein heating the eutectic metal alloy comprises placing a cable heater coupled to the coiled tubing at a downhole location within the wellbore and providing power to the cable heater, wherein the cable heater comprises:
- a heating element configured to generate heat in response to receiving power;
- an insulation layer surrounding the heating element, the insulation layer comprising magnesium oxide; and
- a sheath surrounding the insulation layer, the sheath comprising steel.
3. The method of claim 2, comprising:
- prior to placing the eutectic metal alloy with the coiled tubing into the wellbore, positioning a bridge plug or packer downhole of the downhole location within the wellbore; and
- after positioning the bridge plug or packer and prior to placing the eutectic metal alloy with the coiled tubing into the wellbore, sealing the bridge plug or packer against an inner wall of the wellbore, thereby preventing fluid from flowing further downhole past the bridge plug or packer.
4. The method of claim 3, wherein the eutectic metal alloy has a density in a range of from about 8.0 g/cm3 to about 11.0 g/cm3.
5. The method of claim 4, wherein the particles of the eutectic metal alloy have an average particle size in a range of from about 1 micrometer to about 0.25 centimeters.
6. The method of claim 5, wherein the liquefied eutectic metal alloy has a viscosity in a range of from about 1 centipoise (cP) to about 10 cP.
7. The method of claim 6, wherein the eutectic metal alloy is suspended in a carrier fluid comprising bentonite clay.
8. A system comprising:
- a coiled tubing disposed in a wellbore formed in a subterranean formation, the coiled tubing configured to flow a lost circulation fluid;
- the lost circulation fluid configured to seal a lost circulation zone at a downhole location in the subterranean formation, the lost circulation fluid comprising:
- a eutectic metal alloy comprising a plurality of metals, the eutectic metal alloy having a melting temperature that is less than a melting temperature of each metal of the plurality of metals, the eutectic metal alloy configured to liquefy in response to being heated to a temperature equal to or greater than the melting temperature of the eutectic metal alloy; and
- a carrier fluid comprising a polymer and a crosslinking agent, wherein the eutectic metal alloy is suspended in the carrier fluid, wherein the eutectic metal alloy, in a liquefied state in response to being heated to the temperature equal to or greater than the melting temperature of the eutectic metal alloy, is configured to flow from the wellbore and into the subterranean formation, wherein the crosslinking agent is configured to crosslink the polymer in response to exposure to a specified downhole temperature to form a seal comprising the eutectic metal alloy distributed across a crosslinked polymer matrix, wherein the seal is configured to prevent fluid from flowing from the wellbore and into the subterranean formation; and
- a cable heater coupled to the coiled tubing flowing the lost circulation fluid, the cable heater located at the downhole location, wherein the cable heater is configured to, in response to receiving power at the downhole location, heat the eutectic metal alloy to the temperature equal to or greater than the melting temperature of the eutectic metal alloy to liquefy the eutectic metal alloy.
9. The system of claim 8, wherein the cable heater comprises:
- a heating element configured to generate heat in response to receiving power;
- an insulation layer surrounding the heating element, the insulation layer comprising magnesium oxide; and
- a sheath surrounding the insulation layer, the sheath comprising steel.
10. The system of claim 9, comprising a bridge plug or packer positioned downhole of the downhole location within the wellbore, the bridge plug or packer sealed against an inner wall of the wellbore to prevent fluid from flowing further downhole past the bridge plug or packer.
11. The system of claim 10, wherein the eutectic metal alloy has a density in a range of from about 8.0 grams per cubic centimeter (g/cm3) to about 15.0 g/cm3.
12. The system of claim 11, wherein the density of the eutectic metal alloy is in a range of from about 8.0 g/cm3 to about 11.0 g/cm3.
13. The system of claim 12, wherein the eutectic metal alloy comprises particles having an average particle size in a range of from about 1 micrometer to about 0.25 centimeters.
14. The system of claim 13, wherein the liquefied eutectic metal alloy has a viscosity in a range of from about 1 centipoise (cP) to about 10 cP.
15. The system of claim 14, wherein the viscosity of the liquefied eutectic metal alloy is less than 5 cP.
16. The system of claim 14, wherein the carrier fluid comprises bentonite clay.
17. The system of claim 14, wherein the polymer comprises hydroxyethyl cellulose.
18. A method comprising:
- positioning a packer within a wellbore formed in a subterranean formation;
- expanding the packer to seal against an inner wall of the wellbore, thereby preventing fluid from flowing past the packer;
- flowing a lost circulation fluid through a coiled tubing into the wellbore, the lost circulation fluid comprising: a eutectic metal alloy comprising a plurality of metals, the eutectic metal alloy having a melting temperature that is less than a melting temperature of each individual metal of the plurality of metals; and a carrier fluid comprising hydroxyethyl cellulose and a crosslinking agent, wherein the eutectic metal alloy is suspended in the carrier fluid;
- placing a cable heater coupled to the coiled tubing at a downhole location within the wellbore up hole of the expanded packer;
- after placing the cable heater at the downhole location, providing power to the cable heater, thereby heating the eutectic metal alloy to a temperature greater than the melting temperature of the eutectic metal alloy to liquefy the eutectic metal alloy;
- flowing the liquefied eutectic metal alloy with the carrier fluid from the wellbore and into the subterranean formation, thereby exposing the carrier fluid and the eutectic metal alloy to a specified downhole temperature within the subterranean formation and causing the crosslinking agent to crosslink the hydroxyethyl cellulose and the eutectic metal alloy to solidify to form a seal comprising the eutectic metal alloy distributed across a crosslinked polymer matrix;
- preventing, by the seal, fluid from flowing from the wellbore and into the subterranean formation; and
- drilling through the packer to remove the packer from the wellbore.
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Type: Grant
Filed: Feb 10, 2023
Date of Patent: Jul 16, 2024
Assignees: Newpark Drilling Fluids LLC (Katy, TX), Saudi Arabian Oil Company (Dhahran)
Inventors: Arthur Herman Hale (Houston, TX), Ahmed Said Abdelaziz Amer (Katy, TX)
Primary Examiner: Andrew Sue-Ako
Application Number: 18/167,550
International Classification: E21B 33/12 (20060101); C09K 8/42 (20060101); C09K 8/487 (20060101); E21B 33/138 (20060101); E21B 36/00 (20060101); E21B 36/04 (20060101);